AJmustDIE's ABA Turbo Build Thread

[AJmustDIE]

What's up guys, very recently I blew my transmission in my MKIII.
Sooo, I'm taking the time I have now to take this thing apart (somewhat) and install the part's I've had stacked against my bedroom wall for months now.

The canvas is an already "slammed" Trek on Miro STP-1 Wheels. All work thus far been done by myself.

Official "Before" Photo.


This is how the primary setup is going to be.

• Garrett GT2541r Dual BB Core Oil & Water-cooled Turbo GT2876r
• Frozenboost 600hp Air/Water Intercooler Kit (No I'm not trying to push that number)
• 2.5" Polished Charge Piping
• MK4 2.0 Manifolds and corresponding parts.
• C2 Stage 2 Software
• Bosch 42lb Green Top Injectors

When the build is over I'm swapping out the blown 020 Tranny for an 02A to give me peace of mind and for better gearing.

Also, I will only be running 8 PSI when the build is "completed" after I get the tranny paid for I'm buying a set of JE pistons and IE rods to lower my compression so I can raise the boost. Just so your minds don't wander..

Day One of Build, Deconstruction Time.

Sittin' down takin' a break before I get at it, garage view.


Stock MK3 Upper Manifold Off


Stock Fuel Rail pulled off, probably going to be re-used.


Myself taking the time to pose for a 10 sec timer pic,


MK3 Lower Intake manifold, so damn restrictive.


Shot of the head & cam. Wish I had the money to go to a more aggressive cam but that will come later.


Pile of USELESS junk.


End of Day 1,

-------------------------------------------

Day 2

Here's a peak what the bay is going to be looking like , took about 10-15 hours polishing the AEG Upper Intake.


Here's the baby of a Turbo I'll be workin' with.


Stay tuned men, I'm 19 years old and I'll be doing ALL of the work myself. This is my first turbo build and first time working with a VW's engine. I've got a pretty solid background on what I'm doing. Sub if you support boosted ABA's

[vibrancyy]

Subscribed! Good luck with this! white jetta

[Yeah Right!]

i used to have a white ABA turbo Jetta.

I miss that pig.

Good luck Mang.

[fukdapo9]

watching

[vento86]

aba turbos are fun!! good luck with the project.

[MKIIITOMV]

awesome build deff watching this

[jbigs268]

i shall follow this one!

[AJmustDIE]

Alrighty guys.
Made some progress today in regards to the turbo it's self, more specifically the manifold.

I was being curious to how well the gasket matched up to the turbo manifold yesterday so I lined it up and holy bahjesus. One look and I could tell some gasket matching needed to be done.


(yes I realize the gasket it upside down but that is irrelevant)

Stuck the gasket to the mani and laid some paint down, and got to work!


Good amount of material shaved out.


After correcting some misshapen bumps and such, wahhlahhh!


And the other side.



Now I realize this is not much of an update. But it was critical none the less, those faces on the turbo manifold could have hindered some performance so I know what little time I spent doing this is well worth it. Finished that up, cleaned up and snapped a pic of the Jetta.. I miss her face



On the plus side my buddy picked me up this sweet decal off of ebay



That is all for today.

[vento86]

That 2slow decal is awesome. I'm getting one for my mk1 abat

[AJmustDIE]

That 2slow decal is awesome. I'm getting one for my mk1 abat

I wanna see

[vento86]

I wanna see

Build thread is in my sig but my photobucket account sucks right now and the pics don't work

[DUBSKEE]

watching this

[A3jett]

liking this build

[zachass o2]

Sub if you support boosted ABA's

im building one myself right now

[AJmustDIE]

Build thread is in my sig but my photobucket account sucks right now and the pics don't work

Looks like they're working fine to me! And hot damn! Have you any fingerprints left with all that sanding!? lol.

Sick dude, watching your build now. Wish I had the time to pull mine apart and attack my bay, but that's for another day. I need this damn thing back on the road ASAP. SOWO is commin' around fast!

[jettaiv4turbochrg]

nice

[vento86]

Looks like they're working fine to me! And hot damn! Have you any fingerprints left with all that sanding!? lol.

Sick dude, watching your build now. Wish I had the time to pull mine apart and attack my bay, but that's for another day. I need this damn thing back on the road ASAP. SOWO is commin' around fast!

I JUST upgraded to PB PRO.. and my fingas' hurt! And shaving bays are no joke. It takes a LOT of time. And thanks brotha! Lol

[JohnStamos]

If you are swapping the trans, and installing all the FI related components, just pull the front clip, then pull the entire engine/trans as a unit. You will save a TON o/f time and a TON of frustration.




for doing work.

[AJmustDIE]

If you are swapping the trans, and installing all the FI related components, just pull the front clip, then pull the entire engine/trans as a unit. You will save a TON o/f time and a TON of frustration.




for doing work.

I'm gonna throw this turbo setup together and let my buddy who's gonna tackle the transmission worry about that I have to drive it to his garage after I get the engine running. It's stuck in 3rd gear. lol. But yeah man I'd figured as much. Thanks for lookin' out!

[nfx]

for another 2.0T

I just installed an AEG manifold myself. what is your plan for dealing with the larger then normal holes for the injectors on the lower manifold?

[2point0jetta]

That AEG swap is sexy. Keep up the good work.

[AJmustDIE]

for another 2.0T

I just installed an AEG manifold myself. what is your plan for dealing with the larger then normal holes for the injectors on the lower manifold?

May I see a picture of your setup?

I Unclipped the plastic clip that came on the #42 Injectors, doubled up the rubber o-rings and pushed it in, looks like it's sealing fine but we'll find out when I turn the key and both fuel pumps come on. lol.

In other news, I just bought a welder today. It's nothing special just something to get me by when I come to mounting all the Air/Water Intercooling components. Should have some pics tomorrow of some more progress if it's not raining.

[croutonjack]

here's a birch beer for you since you're underage

[AJmustDIE]

here's a birch beer for you since you're underage

Age didn't stop me when I was in the Army for 2 years.
Damn hernia..

[nfx]

Only real picture I have of the bay... before paint.



The only thing I'd change from this setup is the IAT. I was in a rush so I welded a nut onto a pipe and threw it in there.

Here is my new fix...



1.8T IAT sensor. You can drill 2 holes... tap one for a bolt... grab an o-ring... install and enjoy. Not only is that easier, the 1.8T sensor gets more accurate readings due to the open air element (no heatsoak like the MK3 2.0/VR model)

[jordan_fehlman]

yum

[AJmustDIE]

Looks good man, get that upper polished!

Whats your system specs?

[nfx]

Already started the polishing project... most of the pipes are now polished (not as well as I want, but I'll get there). Manifold is a different story... that'll probably be done next winter.

As far as a setup... nothing too special

rebuilt Garrett T3 .52 trim (.48 hotside)
2-1/2 downpipe back with a highflow cat
FMIC (obviously) with 2-1/4 piping all around
AEG manifold (obviously)
Bosch red tops (30lbers) with C2 stage 1 software (from summer 2007... I think it's ver. 2 software)
Pushing around 11psi - close to 200whp i assume... haven't dyno'd in a while
Autotech 260 cam with lightweight lifters... everything else motor wise is stock
ACT stage 1 clutch (slipping)
BFI Stage .5 motor mount inserts

I've got a clutchnet unit to replace the ACT clutch, along with a new rear main seal and possibily a bolt kit too for the 02O. I'd go stand alone, but the car has to pass plug-in OBD2 emissions where im living, so PNP software is a must and i want stage 2. I'd also love to do some head work... but money is tight, so yeah.

plans for the spring/summer include fixing my leaky exhaust, changing the clutch and associated parts i mentioned earlier, and driving it.

edit: picture of the car

[raymondlee]

hey man sick build

[AJmustDIE]

hey man sick build

Thanks man!


Thought I would share a photo of my intercooler setup with you guys.


If anybody has any questions about the Air/Water setup, I'll be glad to answer them for you.

[ItAintRubbinItAintDubbin]

now that water is going to be sprayed through the cooler to lower the air temp passing through right?

[AJmustDIE]

now that water is going to be sprayed through the cooler to lower the air temp passing through right?

Yes , A Water to Air Intercooler setup is similar in principle to a traditional air to air setup, except that there is water passing through the core of the intercooler instead of air which is responsible for drawing the heat out of the intake air. Water and other coolants disperse heat faster and more efficiently than air can.

After the water makes it's way out of the intercooler it's been heated, it then goes through the Air/Water heat exchanger, it's basically a radiator, as the water moves through the heat exchanger it cools back to ambient air temps. Then it makes it's way to the Ice box, which mine personally will always be filled with chunks of ice, even though the ice box isn't necessary for the setup, you can clearly think of the benefits of passing 40 degree water through the Intercooler

[nfx]

hey hey now i see an all aluminum radiator. what'd you find that worked?

[Dmoneythegreat]

Making me want to keep my 8v and turbo it instead of doing a 16v turbo
Goodluck
I hope you take videos of it running when it's finished

[MM2 Zayas]

Keep it up, 8v is just classier. Cheers